# US 11,299,424 B2 · Pozzolanic compositions containing fly ash and remediation agents for use in cementitious materials

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- Number: US 11,299,424 B2
- Document ID: US11299424B2
- Status: Granted
- Kind: B2
- Application number: 16/877,387
- Filed: 2020-05-18
- Published: 2020-09-03
- Granted: 2022-04-12
- Earliest claimed: 2014-06-25
- Assignees: CR Minerals Company, LLC
- Applicants: CR Minerals Company, LLC
- Inventors: Joseph Earl Thomas; Richard Douglas Carter; Jeffrey Alexander Whidden
- Web page: https://patentgrep.com/patent/US11299424B2

## CPC

- C04B 7/26: from raw materials containing flue dust {, i.e. fly ash (C04B7/243 takes precedence)}
- C04B 18/088: {in high volume fly ash compositions}
- C04B 7/12: Natural pozzuolanas; Natural pozzuolana cements; {Artificial pozzuolanas or artificial pozzuolana cements other than those obtained from waste or combustion residues, e.g. burned clay; Treating inorganic materials to improve their pozzuolanic characteristics (cements containing slag C04B7/14)}
- C04B 14/14: Minerals of vulcanic origin {(granite C04B14/048)}
- C04B 18/08: Flue dust {, i.e. fly ash}
- C04B 18/146: {Silica fume}
- C04B 28/02: containing hydraulic cements other than calcium sulfates
- C04B 28/021: {Ash cements, e.g. fly ash cements (fly ash as filler C04B18/08); Cements based on incineration residues, e.g. alkali-activated slags from waste incineration (alkali-activated combustion residues as such C04B7/243; mixtures of the lime-pozzuolane type C04B28/18); Kiln dust cements}
- C04B 28/18: containing mixtures of the silica-lime type
- C04B 40/0039: {Premixtures of ingredients}
- C04B 2111/2015: {Sulfate resistance}
- C04B 2111/2023: {Resistance against alkali-aggregate reaction}
- C04B 2111/21: Efflorescence resistance
- C04B 2111/26: Corrosion of reinforcement resistance
- Y02P 40/10: Production of cement, e.g. improving or optimising the production methods; Cement grinding
- Y02W 30/91: Use of waste materials as fillers for mortars or concrete
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02W: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT

## Abstract

It has been unexpectedly discovered that the addition of a natural or other pozzolan to non-spec fly ash significantly improves the properties of the non-spec fly ash to the extent it can be certified under ASTM C618 and AASHTO 295, as either a Class F or Class C fly ash. The natural pozzolan may be a volcanic ejecta, such as pumice or perlite. Other pozzolans may also be used for this beneficiation process. Many pozzolans are experimentally tested and may be used to beneficiate non-spec fly ash into certifiable Class F fly ash. Additionally, this disclosure provides a method of converting a Class C fly ash to a more valuable Class F fly ash. This discovery will extend diminishing Class F fly ash supplies and turn non-spec fly ash waste streams into valuable, certified fly ash pozzolan which will protect and enhance concrete, mortars and grouts.

## Claims

### Claim 1

A pozzolanic composition for use in concrete, said composition comprising coal ash combined with a natural pozzolan, wherein said natural pozzolan is present in a concentration of about 1 wt % to about 99 wt %, wherein the combination of said natural pozzolan with said coal ash results in said pozzolanic composition meeting a specification for pozzolanic mixtures, pozzolan admixtures, or supplementary cementitious materials in concrete under ASTM and/or AASHTO.

### Claim 2 (depends on 1)

The pozzolanic composition of claim 1, wherein said natural pozzolan is present in a concentration of about 10 wt % to about 90 wt %.

### Claim 3 (depends on 1)

The pozzolanic composition of claim 1, wherein a weight ratio of said natural pozzolan to said coal ash is from about 0.01 to about 100 parts natural pozzolan divided by parts coal ash.

### Claim 4 (depends on 3)

The pozzolanic composition of claim 3, wherein a weight ratio of said natural pozzolan to said coal ash is from about 0.1 to about 10 parts natural pozzolan divided by parts coal ash.

### Claim 5 (depends on 1)

The pozzolanic composition of claim 1, wherein said natural pozzolan is a volcanic ash with pozzolanic properties.

### Claim 6 (depends on 1)

The pozzolanic composition of claim 1, wherein said natural pozzolan is a material defined as a natural pozzolan pursuant to ASTM and/or AASHTO.

### Claim 7 (depends on 1)

The pozzolanic composition of claim 1, wherein said coal ash is a non-spec ash that does not meet any specifications for pozzolanic mixtures, pozzolan admixtures, or supplementary cementitious materials in concrete under ASTM and/or AASHTO.

### Claim 8 (depends on 7)

The pozzolanic composition of claim 7, wherein said coal ash contains less than 50 wt % of the sum of weight percent silicon dioxide, weight percent aluminum oxide, and weight percent iron oxide.

### Claim 9 (depends on 1)

The pozzolanic composition of claim 1, wherein said coal ash meets a first specification for pozzolanic mixtures, pozzolan admixtures, or supplementary cementitious materials in concrete under ASTM and/or AASHTO, wherein said combination of said natural pozzolan with said coal ash results in said pozzolanic composition meeting a second specification for pozzolanic mixtures, pozzolan admixtures, or supplementary cementitious materials in concrete under ASTM and/or AASHTO.

### Claim 10 (depends on 9)

The pozzolanic composition of claim 9, wherein said coal ash contains at least 50 wt % but less than 70 wt % of the sum of weight percent silicon dioxide, weight percent aluminum oxide, and weight percent iron oxide, wherein said first specification requires at least 50 wt % of the sum of weight percent silicon dioxide, weight percent aluminum oxide, and weight percent iron oxide, and wherein said second specification requires at least 70 wt % of the sum of weight percent silicon dioxide, weight percent aluminum oxide, and weight percent iron oxide.

### Claim 11 (depends on 1)

The pozzolanic composition of claim 1, said composition further comprising an additive to adjust water demand of said composition in concrete.

### Claim 12 (depends on 1)

The pozzolanic composition of claim 1, wherein said composition is present in a cementitious mixture.

### Claim 13 (depends on 12)

A concrete product or structure comprising aggregate and said cementitious mixture of claim 12, or a reaction product thereof.

### Claim 14

A method of producing a pozzolanic composition for use in concrete, said method comprising:
providing a source of coal ash;
providing a natural pozzolan; and
combining said coal ash with said natural pozzolan, to produce a pozzolanic composition meeting a specification for pozzolanic mixtures, pozzolan admixtures, or supplementary cementitious materials in concrete under ASTM and/or AASHTO, wherein said coal ash is upgraded by the presence of said natural pozzolan to enhance its pozzolanic properties prior to addition of said pozzolanic composition to said concrete.

### Claim 15 (depends on 14)

The method of claim 14, wherein said natural pozzolan is present in a concentration of about 1 wt % to about 99 wt % in said pozzolanic composition.

### Claim 16 (depends on 15)

The method of claim 15, wherein said natural pozzolan is present in a concentration of about 10 wt % to about 90 wt % in said pozzolanic composition.

### Claim 17 (depends on 14)

The method of claim 14, wherein said natural pozzolan is a material defined as a natural pozzolan pursuant to ASTM and/or AASHTO.

### Claim 18 (depends on 14)

The method of claim 14, wherein said coal ash is a non-spec ash that does not meet any specifications for pozzolanic mixtures, pozzolan admixtures, or supplementary cementitious materials in concrete under ASTM and/or AASHTO.

### Claim 19 (depends on 14)

The method of claim 14, wherein said coal ash meets a first specification for pozzolanic mixtures, pozzolan admixtures, or supplementary cementitious materials in concrete under ASTM and/or AASHTO, wherein said combination of said natural pozzolan with said coal ash results in said pozzolanic composition meeting a second specification for pozzolanic mixtures, pozzolan admixtures, or supplementary cementitious materials in concrete under ASTM and/or AASHTO.

### Claim 20 (depends on 19)

The method of claim 19, wherein said coal ash contains at least 50 wt % but less than 70 wt % of the sum of weight percent silicon dioxide, weight percent aluminum oxide, and weight percent iron oxide, wherein said first specification requires at least 50 wt % of the sum of weight percent silicon dioxide, weight percent aluminum oxide, and weight percent iron oxide, and wherein said second specification requires at least 70 wt % of the sum of weight percent silicon dioxide, weight percent aluminum oxide, and weight percent iron oxide.